NSRP Panel Meeting – San Diego Presented by: Bryan J. Miller Topgallant® Product Data Management and Collaborative Software for Shipbuilding

2 Copyright © 2006 Atlantec Enterprise Solutions Agenda I.Company and Topgallant® Overview II.Released Products III.Under Development IV.Research Programs V.US vs. EU shipbuilding VI.How Atlantec-es can help U.S. shipbuilders

3 Copyright © 2006 Atlantec Enterprise Solutions Atlantec Enterprise Solutions Focused on interoperability solutions for the shipbuilding industry Founded in 1999, steadily growing since Offices in Germany and in the USA Clients Partners HDW, Germany Dassault Systems (CAD) Aker Yards Germany AVEVA (Tribon-CAD) Aker Yards Finland Alma (Nesting-CAM) NWSC, Carderock Logimatic (ERP) Flensberger ShipConstructor U.S. Research Partners Electric Boat Marinette Marine NGSS Penn State ARL Gibbs& Cox Bollinger Shipyards DRS NGNNS UNO

4 Copyright © 2006 Atlantec Enterprise Solutions Topgallant® Collaboration for Design and Production Data Model based on ISE STEP Schema A standards-based information management system designed for managing complex information exchanges and for collaboration in design and production

5 Copyright © 2006 Atlantec Enterprise Solutions Topgallant® Manages Distributed Information flow –Product Data Management (versions, dependencies) –process/workflow support and monitoring Enables Design and Production at Multiple Sites Decouples Design/Production systems Based upon Industry Standards –includes STEP: ISO (AP214, 215, 216, 218, 227 & 238), WfMC and X.500 –XML representation –ISE compliant

6 Copyright © 2006 Atlantec Enterprise Solutions Topgallant® Change Manager Installed at HDW in Germany Now part of Thyssen Krupp Marine Group. HDW has built merchant ships, surface combatants, and submarines Change Manager sequences the SAP ERP System with the Tribon design system. Last minute design changes are monitored by Change Manager and makes sure that all changes are synchronized with the ERP system.

7 Copyright © 2006 Atlantec Enterprise Solutions Topgallant® Plate Production 1 st Application from CAD-CAM-Connector SBIR installed at Aker Germany Automated Nesting System: Complete Plate Processing and Management System Extracts all steel plates from CAD-system plus externally defined geometries Selects and releases complete assemblies for nesting Eliminates manual nesting - automatic nesting jobs Employs production rules allowing collaboration between yards and design agents Manages the steel plate storage Controls nesting software

8 Copyright © 2006 Atlantec Enterprise Solutions Topgallant® Assembly Production 2 nd CAD-CAM-Connector Application Changes Design to Production Geometry based on predicted material deformation Generates an assembly tree and assigns production processes Applies customized dimensional rules Provides feedback loop for production dimensional data; bridges Engineering & Quality Control Step 2: Assign assembly process Step 5: Update files for nesting Step 3: Apply total shrinkage values Step 1: Extract detailed hull design Step 4: Update detailed design

9 Copyright © 2006 Atlantec Enterprise Solutions Topgallant® QADesktop 1.Defines Production Resources: Buildings Facilities Assembly Levels Production Control Path Fabrication Matrix Production-specific Rules 2. User-defined rules 3.Multiple-Site Production Example of a production control path as defined by a fabrication matrix

10 Copyright © 2006 Atlantec Enterprise Solutions Aker Yards Finland Project Implementation at Turku, Helsinki, and Rauma Shipyards First Application: Genesis Class (220K GT Cruise Ship) Applies dimensional quality control to grand block assemblies - Simulates Grand Block assemblies –Predicts shrinkage based on past empirical measurements –Feeds dimensional changes back to CAD system –Adjusts piece part dimensions pre-fabrication to remain true to designed dimensions

11 Copyright © 2006 Atlantec Enterprise Solutions Topgallant® Tx-Check Checks Data Quality of Engineering Designs Proposed development work for Thyssen Krupp Marine Systems(TKMS) for data quality software which checks: Structural guidelines Consistency with special formats Manufacturing defaults Logical dependence in the data Source of errors Designed for multiple -site collaboration

12 Copyright © 2006 Atlantec Enterprise Solutions QualiShip – Data Verification Project Aker Yards, Germany, Atlantec-es, Fr. Lürssen Werft, Germanischer Lloyd, SMK Ingenieurbüro, Universität Rostock Development of enterprise-specific logical arguments regarding quality-assurance in the design and production Reduce production re-work by securing correct working documents, and automating inspections to a defined quality criteria, Early error detection Minimize quality control checking of engineering data Increase quality of ship attribute data Addresses quality issues with data: has every point value been defined, logical curves created, appropriate design rules applied and satisfied?

13 Copyright © 2006 Atlantec Enterprise Solutions Common Parts Catalog – (CPC) Information Management System Part data standardization Inter-shipyard cataloging system that enables part and document data management Parts Identification per specific hull Enables data sharing across the shipbuilding industry, including: –New construction yards –Supply chain –Military & non-military customers

14 Copyright © 2006 Atlantec Enterprise Solutions Common Parts Catalog Part Design Class SBIR ONR SBIR Phase II collaborative effort between MMC, DRS, ShipConstructor, Gibbs & Cox and Atlantec-es Extends CPC Benefits to Engineering Plan to develop STEP-based interoperability tools to help exchange design data between: –Shipyards,- Vendors –Design agents,- Navy –Other defense contractors Parts in neutral format - STEP Compliant Enables Shipyards, Design Agents, Suppliers, and Systems Integrators to share parts models using different CAD Systems Added 3D viewing capability

15 Copyright © 2006 Atlantec Enterprise Solutions Assembly Simulation Automating Assembly Planning through Simulation Phase I SBIR awarded 23 rd March, 2007 PSU-ARL, Marinette Marine, Atlantec-es Benefits Automate simulation models Increase planning fidelity Optimize work sequencing What-if, trade-off studies Reduce planning time Rapidly adjust for design changes Rapidly adjust for production changes Design Product Models Topgallant® Assembly Production Module Standardized Facility Model Manufacturing Product Models Discrete Event Simulation (Flexsim©) QA Desktop

16 Copyright © 2006 Atlantec Enterprise Solutions Cross-Domain Interoperability Project DOD/Army Research Lab STTR Project Status: In Award Negotiations Partners - UNO and Intergraph Project Objective: Develop an adaptive cross-domain interoperability toolkit

17 Copyright © 2006 Atlantec Enterprise Solutions U.S. Shipyard Customers

18 Copyright © 2006 Atlantec Enterprise Solutions U.S. vs. EU Yards - Contrasts US EU Low-level of production Ship Factory Design Focused Production Focused Cost Plus Fixed Price Large Work Force Small Work Force Multiple Change Orders Product–few changes Low degree of Automation Highly Automated General Purpose Software Shipbuilding Software Large Vendors Small Vendors In-House Focus Sub-Contractor Focus *Applies mainly to large primes. Second tier resembles EU yards in several categories

19 Copyright © 2006 Atlantec Enterprise Solutions Topgallant Advantages Supports collaboration in engineering and production Supports Design and Production at separate locations Manages last-minute changes in design or production Reduces business disruptions due to software changes / upgrades Integrates and automates Engineering and Production Provides powerful production support tools Provides Configuration Management - Hull effectivity ( manages changes by contract and by hull) Increases productivity in steel production and hull assembly operations

20 Copyright © 2006 Atlantec Enterprise Solutions How Atlantec-es Can Help US Yards Topgallant® is already used by three Major European Shipyards Focused on Production Support Applications which were identified as major problem in benchmarking study Reduce rework and manual data entry Lower software implementation costs A solution in some major NPDI areas Provide affordable automation to the Second Tier